vok skadegruppens temadag 2019 · turbine loss scenario #1: flow path components practical loss...

Stockholm, Sweden, November 13 2019

VoK Skadegruppens temadag 2019

Mathijs Bolin – Account Engineer

“Systematic approach to loss prevention resulting from practical loss examples”

FM Global – A unique company

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One focus, one goal

Mutuality offers advantages

Majority of loss is preventable

Power Generation Losses (incl. paper industry)

Turbine Losses - Some Statistics

Component failure: 7/yearOverspeed: 1/year

Safety device failure: 8/year

Lube oil fire: 1/year

16 losses/year

Contributing factor:

Lube oil starvation: 3/year

Turbine loss scenario #1: Flow path components

Flow path component failure is highly related to:

steam purity (solid, liquid or vaporous contamination) & quality (moisture).

Turbine loss scenario #1: Flow path components

Turbine loss scenario #1: Flow path components

Turbine loss scenario #1: Flow path components

Practical loss prevention references

▪ Operate within design operating parameters (load, temperature, etc.). - Standard Operating Procedures and Operator Training are critical.

▪ Control the steam purity/quality.- Understand the sampling system installation (placement, probes, etc.).

- Conduct regular online/offline analysis. Ensure regular equipment servicing and calibration.

- Review analysis results against set limits, correct deviations and review trends.

Turbine loss scenario #2: Loss of lube oil

Turbine loss scenario #2: Loss of lube oil

Turbine loss scenario #2: Loss of lube oil

Main lube oil pump (MOP)

Auxiliary lube oil pump (AOP)

Emergency DC oil pump (ELOP)

MOP

Utility

AOP

Utility

ELOP

UPS

ELOP

DCs

GCB control

Turbine loss scenario #2: Loss of lube oil

INCIDENCE BRIEF DESCRIPTION

• ONE OF REDUNDANT DIRECT CURRENT (DC) POWER SOURCES WAS

ISOLATED FOR ONE BANK OF BATTERIES REPLACEMENT.

• OPERATION ENGINEER ASSIGNED WITH THE TASK OF NORMALIZING THE

POWER SUPPLY BY CONNECTING BACK THE ISOLATED POWER SOURCE.

• INSTEAD OF CONNECTING BACK THE POWER SOURCE NOT IN SERVICE, HE

DISCONNECTED THE ONLY OTHER SOURCE FEEDING THE VITAL AREAS.

ELOP

UPS

ELOP

DCs

GCB control

Turbine loss scenario #2: Loss of lube oil

Main lube oil pump (MOP)

Auxiliary lube oil pump (AOP)

Emergency DC oil pump (ELOP)

MOP

Utility

AOP

Utility

Turbine loss scenario #2: Loss of lube oil

Practical loss prevention references

▪ Ensure free flow of oil supply from DC pump to bearings:

- Prevent isolation of (emergency) oil supply by valves, coolers, filters, etc.

▪ Arrange for adequate DC pump start:- Prevent isolation valves in pressure sensing lines.

- Allow DC pump start upon loss of signal.

- Test pump start regularly – in a safe manner (SOP)!

▪ Create an adequate AC/DC power supply:

- Prevent manual isolation of both battery banks.

- Avoid (if possible) overcurrent or overtemperature interlocks to protect the DC motor.

- Consider a common DC buss bar as a potential single point of failure.

Turbine loss scenario #3: Overspeed

Main Steam – Emergency Stop Valve

Extract Steam – Non-Return Valves

Overspeed Protection:- Electronic

- Mechanical

Key Safety Devices

FM Global’s view on key loss prevention areas

A systematic approach to understand the

functioning of safety devices and to inspect, test

and maintain these devices is critical.

A systematic approach is needed to develop

Standard and Emergency Operating Procedures

and to train Operators to follow the procedures.

A systematic asset integrity program should

focus on Maintenance Strategy and Planning,

followed by Execution, Reporting and Analysis.

Key loss prevention focus areas

Evaluation

Number of losses

0

20

40

60

80

100

<5 år >10 år

0

500

1 000

1 500

2 000

2 500

3 000

<5 år >10 år

Magnitude of losses (MSEK)

Zachariah Allen – Founder of FM Global in 1835

Evaluation

The majority of all

loss is

preventable!

FM GlobalInsurerFMGlobal@FMGlobalFM Global

mathijs.bolin@fmglobal.com

Thank you! Questions?